Ferrule assembly for paint brushes



Jan. 29, 1957 H. P. MCMILLAN FERRULE ASSEMBLY FOR PAINT BRUSHES FiledDec. 10, 1951 INIIIIN HllillUIlUINII/lilllml|||um||||||||u|mn UnitedStates PatentO" 2,779,043 FERRULE ASSEMBLY Fon PAINT BRUSHES Hugh l.McMillan, Baltimore, Md., assiguor to Samuel M. Dell and Company,Incorporated, a corporation of Maryland Application December 10,1951,'Serial No. 260,789

S Claims. (Cl. 15-193) This invention relates to brush construction andparticularly concerns a simplified and improved ferrule assembly havinga novel handle receiving and bristle securing unit.

lt is well known to secure bristles in a brush' ferrule with adhesiveplastic material, thereby to provide low quality and low costconstructions. Considerable difficulty has been experienced, however, inmanufacturing high quality brushes at reasonable cost by reason of theproblems encountered in securely retaining the bristles so they will notshed. While schemes have heretofore been suggested, none has offered afeasible method of manufacturing reasonably priced quality brushes.

An important object of the present invention is to provide an improvedhigh quality brush With bristles firmly and securely retained Iin theferrule and having no t tendency to shed singly orseverally.

A further object of the present invention is to provide a high qualitybrush construction which may bemannfactured at reasonable cost.'

Another object of the present invention is to provide a brush having abristle and handle securing unit made of a plurality of parts easily andinexpensively manufactured and readily assembled.`

In the attainment of thesefand other vobjects,"one"of the major featuresof this 'invention resides in forming the brush 'ferrule with channelsarranged to'pjro'vide a socket for a plate which maybe snapped intoposition and securely heldinthe ferrule without additional fasteningmeans.' Another feature 'concerns embedding lthe buttends of'th'e"brush"bri`stles in plastic material' and cementing the integralmass to the pla'te l'ocke'din the ferrule thereby providing a rigid,durable and easily assemble'd` construction.'

Other objects land advantages'willl appear from the followingldescription when read in the light of thea'ccom-" panying drawings,wherein:

Figrl isa side view of a completely'. assembled 'brush havinga Vferruleunit constructedy inaccordance .Wi'th'fthe present-invention.

Fig. 2 is a partial vertical section taken along lines 2 2 of Fig. 1.

Fig. 3 is a horizontal section taken along lines 3--3 of Fig. 2, withthe upper layer of plastic material absent.

Fig. 4 is a vertical section taken through a ferrule unit embodying thefeatures of this invention as it appears during an intermediate state ofmanufacture.

Fig. 5 is a similar vertical section taken through the same ferrule unitas it appears during a later intermediate stage of manufacture.

In the preferred form of this invention illustrated in Fig. 1, brush 11has a handle 12 which is secured within an elongated ferrule 13 as bynails 14. Bristles 15 are contained within the ferrule 13 and extendtherefrom as in the conventional manner shown.

Ferrule 13 is formed on its inner surface with channels 2,779,043Fatented dan. 293, 1&5?

2 16 around its walls, the channels being disposed in a planeperpendicular to the longitudinal axis of the brush. @ne of thesechannels provides a socket for a separate plate 17l (Fig. 2) within anddisposed transversely of the ferrule 13.

Preferably, the ferrule of this invention is constructed from blanks ofresilient material preformed with `channels and shaped into the tubularform shown in Fig. 3. Lap joint 18 or any similar joint may be used tosecure together the butt ends of the blank and thereby provide a rigid,elongated tubular structure. Opposite walls 19, 2t), however, retain theinherent flexibility and resiliency cf theferrule material by reason oftheir extended length, wnichpermits inward and outward movement of thewalls 19,20, and temporary distortion from the regular tubular formofthe ferrule.

By the present invention, the lateral width of plate 17 is made greaterthan the width of the ferrule above and below the portions provided withchannels'l, the

4opposite side walls of the ferrule being so formed to accommodate thewide plate. Because of theresiliency of fhe'ferrule walls 19, 2t), plate17 may be easily snapped into position in the socket provided bythe-channelv 16 which is situated intermediate the open ends of theferrule and spacedv a short distance from the lower end of the ferrule,as viewed in Fig.` l, whereinit will'be securely locked.

As illustrated in Fig. 3, ends 21, 22, of plate v17 are preferablyspaced from the adjacent ferrule Walls 23, 24 respectively. Thisfeatureallows the rectangular plate 17 vto be inserted sideways into theferrule 13 and subse'quentlyturned and snapped into position in thesocket. Butas other forms and constructions for plate and ferruleassembly having the interlocking feature disclosed vmay be utilized,equivalent arrangements may be adopted without departing from theintended scope of the invention as limited by the claims.

Figs. `4 and 5 disclose intermediate stages of manufac` .fand the buttends embedded in a layer of plastic material 26 present on the undersideof plate 17. Rubber or yother similar adhesive plastic4 well known inthe art may be utilized'for the embedding material.

Fig. 5 shows a 'later stage of manufacture of the brush -whereinadditional plastic material comprising a layer`27 on theupper side ofplate 17 and extending through perforations l25 '(at 28) and in thespaces`29, 30 lis used for securing l'the bristles 15 in the ferrule 13.Taking the assembly in the form shown in Fig. 5 andfasten'ing abrushih'an'dle therein to form the assemblage'shown in Fig. f2 completesthe: manufacture of lthe brush.V

Referring to the construction shown in Fig. l and Fig. 2, nails 14perform an additional function to securing the handle 12 within theferrule. In constructions well known in the prior art, nails, rivets orthe like are used solely for securing a handle and are usually fastenedtransversely in the ferrule in the region of the mass of bristlescontained therein. Nails or rivets driven through the mass of bristlesare liable to split or cut the bristles, which results in the brushfingering during use.

The nails are disposed in the tubular ferrule in a region where nobristles are contained, therefore weakening or cutting of the bristlesdoes not occur, and the serious disadvantages present in the prior artstructures are eliminated. i

It is usual in brush manufacture to provide a work table having a blockwith a cross sectional area corre- .J spending to the cross sectionalarea of the ferrule, The block is provided with a smooth flat uppersurface and is of such a thickness that it extends into the ferrule to apoint (when the ferrule is inverted) adjacent the lower or bristle edgeof the socket providing channels.

In manufacturing the brush of this invention a knot of bristles isinserted to be contained in the ferrule with their butt ends adjacentthe handle end or upper edge of the ferrule and their iiag endsextending from the lower end of the ferrule. The fcrrule is theninverted and forced down over the block which serves to displace thebristles and position the knot with the butt ends of the bristlesadjacent the lower edge of the channels.

After removing the ferrule from the block, plastic material is poured inthe handle end of the ferrule over the mass of bristles. Sufficientplastic material is used to provide a layer of substantial thicknessextending over the cross sectional area of the ferrule and embedding thebutt ends of the bristles. The ferrule with the bristles in place isremoved in its entirety and placed within a dry kiln to allow theplastic material to set.

In practise, after the plastic material has at least partially set, theperforated plate is snapped into place in the socket within the ferrnle.The ferrule, with the perforated plate in place and the bristlesembedded in the layer of plastic material adjacent the plate, is thenpositioned with the bristles extending downwardly and additional plasticmaterial is poured into the upper end of the ferrule in sufficientquantity to provide a layer of substantial thickness on the upper sideof the perforated plate with material extending through the perforationsin the plate and into the areas adjacent the ends of the plate.

The ferrule, now containing the bristles and the perforated plate, isplaced for complete drying in a kiln.

When the mass of plastic has set, the embedded bristles land the plateare securely bound within the ferrule, If desired, the perforated platemay be spot-welded, or similarly fastened, at one or several placesalong the edges to the ferrule- A handle of wood, plastic or similarmaterial may then be secured in the ferrule unit with nails or the liketo complete the brush manufacturing process.

Modifications may be effected without departing from the spirit of theinvention as dened in the appended claims.

I claim:

1. In a brush, a ferrule having inner Walls thereof channeled to form asocket, said socket being disposed intermediate the open ends of saidferrule, a separate perforated plate locked in the socket within anddisposed transversely of said ferrule, the opposite end edges of saidplate being spaced from the adjacent Walls of said ferrule, plasticmaterial comprising layers on the under and upper sides of said plateand extending through the perforations of the plate binding the layerstogether, and bristles having their butt ends embedded in the layer ofplastic material on the underside of said plate.

2. A brush having a handle receiving and bristle securing unitcomprising in combination, a ferrule having the opposite walls 'thereofchanneled to form a socket, said socket being disposed intermediate theopen ends of said ferrule, a separate perforated plate locked in thesocket within and disposed transversely of said ferrule, the oppositeend edges of said plate being spaced from the adjacent walls of saidferrule, and plastic material comprising layers on the under and uppersides of said plate and extending through the perforations of the plateand into the area between the end portions of said plate and theadjacent walls of the ferrule binding the layers together, said layer ofplastic material on the underside of said plate embedding the butt endsof the bristles.

3. In a brush: an elongated ferrule of resilient material having theopposite walls thereof channeled to provide a socket, said socket beingdisposed intermediate the open ends of said ferrule, said socket beingdisposed in a plane perpendicular to the longitudinal axis of the brush;a separate perforated plate locked in the socket within and disposedtransversely of said ferrule, the opposite end edges of said plate beingspaced from the adjacent Walls of said ferrule; plastic materialcomprising layers on the under and upper sides of said plate andextending through the perforations of the plate and into the areabetween the end portions of said plate and the adjacent walls of theferrule binding the layers together, and bristles contained in saidferrule and extending therefrom having their butt ends embedded in thelayer of plastic material on the underside of said plate.

4. A brush having a handle-receiving and bristle-securing unitcomprising in combination, a ferrule having the inner walls thereofchanneled to form a socket, said socket being disposed intermediate theopen ends of said ferrule, a perforated plate locked in the socketWithin and disposed transversely of said ferrule, an end edge of theperforated plate being spaced from the adjacent wall of the ferrule topermit the plate to be snapped into said socket, plastic material in theferrule embedding said plate and the butt ends of the bristles, andmeans disposed in a bristle-free region of said ferrule for securing thehandle in theferrule.

5. In a brush, a ferrule having the inner Walls thereof channeled toform a socket, said socket being disposed intermediate the open ends ofsaid ferrule, a perforated plate locked in the socket within anddisposed transversely of the ferrule, plastic material in the ferruleembedding the plate, and bristles having their butt ends embedded inplastic material on the underside of the plate, an end edge of saidplate being spaced from the adjacent wall of the ferrule to therebypermit the plate to be snapped into the socket.

References Cited in the le of this patent UNITED STATES PATENTS2,080,821 Jacob May 18, 1937 2,316,870 Jacob Apr. 20, 1943 2,508,931Simms May 23, 1950 2,562,716 Hervey July 31, 1951 2,641,014 Sauter June9, 1953

